U.S. patent number 7,980,040 [Application Number 10/543,901] was granted by the patent office on 2011-07-19 for anchor sheet positioning and connection system.
This patent grant is currently assigned to Tac-Fast Georgia L.L.C.. Invention is credited to John Anthony Pacione, Joseph Rocco Pacione, Franz Rittmannsberger, Hubert Schreimeier.
United States Patent |
7,980,040 |
Pacione , et al. |
July 19, 2011 |
Anchor sheet positioning and connection system
Abstract
Attachment devices are described for attaching and locating
overlapped anchor sheets while allowing for some relative movement
as to expansion and contraction. Generally, the devices are a
male/female connection on corresponding sheets and expansion
openings or apertures surrounding either the male or female part to
provide for areas of flexibility to provide for possible movement
of either the male or female part.
Inventors: |
Pacione; Joseph Rocco
(Newmarket, CA), Pacione; John Anthony (Newmarket,
CA), Rittmannsberger; Franz (Richmond Hill,
CA), Schreimeier; Hubert (Fohnsdorf Sillweg,
AT) |
Assignee: |
Tac-Fast Georgia L.L.C.
(Atlanta, GA)
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Family
ID: |
32825346 |
Appl.
No.: |
10/543,901 |
Filed: |
January 29, 2004 |
PCT
Filed: |
January 29, 2004 |
PCT No.: |
PCT/CA2004/000116 |
371(c)(1),(2),(4) Date: |
March 10, 2006 |
PCT
Pub. No.: |
WO2004/066794 |
PCT
Pub. Date: |
August 12, 2004 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20060185303 A1 |
Aug 24, 2006 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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60443563 |
Jan 30, 2003 |
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Current U.S.
Class: |
52/584.1;
52/591.3 |
Current CPC
Class: |
E04B
1/28 (20130101); A47G 27/0468 (20130101); E04B
1/415 (20130101); F16B 5/06 (20130101); E04B
5/43 (20130101) |
Current International
Class: |
E04B
5/02 (20060101); E04B 5/43 (20060101) |
Field of
Search: |
;52/584.1,796.1,698,582.1,506.05,591.1,591.3
;403/169,170,174,348,349 ;411/522 |
References Cited
[Referenced By]
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WO |
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Other References
InterfaceFLOR, Spring Catalog, 2006, pp. 1-56, Canada. cited by
other.
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Primary Examiner: Tran; Khoi
Assistant Examiner: Holloway; Jason
Attorney, Agent or Firm: Hunter; Christopher N. Gray; Brian
W. Norton Rose OR LLP
Parent Case Text
This application is a national phase entry of PCT/CA2004/000116
filed Jan. 29, 2004 designating the United States, which claims
priority from U.S. Patent Application No. 60/443,563 filed Jan. 30,
2003. All of these applications are incorporated herein by
reference. International Patent Application No. PCT/CA2004/000116
was published in English under Article 21 of the Patent Cooperation
Treaty under WO 2004/066794 on Aug. 12, 2004.
Claims
The invention claimed is:
1. A first sheet member to connect to an overlapped second sheet
member to form a substantially horizontal surface comprising the
following: (a) the first sheet member being a regular geometric
shape and having at least one edge, a first surface, and a
generally arcuate countersunk surface below the level of the first
surface and at the edge of the geometric shape; (b) the first sheet
member having in the countersunk portion a first aperture, for
receiving a second male member of the overlapped second sheet; (c)
the first sheet provided on two opposite sides of the first
aperture with second and third apertures proximate to the first
aperture, so as to create areas in the sheet of increased
flexibility about of the first aperture adjacent the second and
third apertures to permit movement of the first sheet member
relative to the second sheet member when the second male member is
located within the first aperture.
2. The first sheet member of claim 1 in which the first aperture is
circular.
3. The first sheet member of claim 2 in which are contained means
to aid in registering the first member circumferentially in
relation to the overlapped second male member.
4. The sheet member of claim 1 having its first surface
substantially covered in hooks, being one-half of a hook and loop
attachment system.
5. The sheet member of claim 4 in which the sheet is made of a
relatively thin plastic between 0.020 inches and 0.75 inches.
6. The sheet member of claim 5 in which the plastic is
polypropylene or polyethylene.
7. The sheet member of claim 6 which has a resilient layer attached
to a second opposite surface.
8. A sheet surface area comprising: a first sheet member being a
regular geometric shape and having at least one edge, a first
surface, and a generally arcuate countersunk portion below the
level of the first surface and at the edge of the geometric shape,
the first sheet having, in the countersunk portion, a first
aperture having a first size and a channel of a smaller size than
the first aperture and connecting to the first aperture; and a
second sheet member with at least an overlapping portion of a
thickness matching the thickness of the countersink of the first
sheet member and having a male member with a stem and a head, the
head having a second size corresponding to but smaller than the
first aperture and larger than the size of the channel, and in
which the stem has a thickness corresponding to the size of the
channel of the first sheet member so that the head of the second
sheet member can be inserted into the first sheet member through
the first aperture and a shaft moved into the channel to prevent
upward motion of the head and of the first sheet member in relation
to the second sheet member, and in which the second sheet member
contains first areas of expansion and flexibility on opposite sides
of the male member, so as to provide for flexible planar movement
of the second sheet member in relation to the first sheet member
when the shaft is located within the channel.
9. The sheet surface area of claim 8, wherein the areas of
expansion are first expansion apertures.
10. The sheet surface area of claim 9, wherein the first sheet
member contains second areas of expansion and flexibility on
opposite sides of the first aperture and the channel.
11. The sheet surface area of claim 10, wherein the second areas of
expansion are second expansion apertures.
12. The sheet surface area of claim 10, wherein the first surface
is substantially covered in hooks of a hook and loop attachment
system.
13. The sheet surface area of claim 12, wherein the first sheet
member comprises a plastic and is of a thickness between 0.020
inches and 0.75 inches.
14. The sheet surface area of claim 13, wherein the plastic is
selected from the group consisting of polypropylene and
polyethylene.
15. The sheet surface area of claim 14, wherein the first sheet has
a resilient layer attached to a second opposite surface.
16. The sheet surface area of claim 15, wherein the first aperture
is circular.
17. The sheet surface area of claim 16, wherein the head of the
male member is circular.
18. A sheet surface area of at least two overlapped sheets,
comprising: i) a first anchor sheet being a regular geometric shape
and having at least one edge, a substantially horizontal surface,
and a generally arcuate countersunk portion from the horizontal
surface located at the edge of the geometric shape; ii) a female
aperture within the countersunk portion; and iii) a second anchor
sheet having at least an overlap portion of a thickness to fit into
the countersunk portion of the first anchor sheet to present a
substantially planar surface, the second sheet having a male member
having, in combination with the female aperture, means to be
inserted and retained in the female aperture, in which at least one
of the male member or the female aperture have expansion openings
or areas of flexibility on at least one of the first or second
sheets proximate to at least one of the male member or the female
aperture to provide for movement of at least one of the male member
or the female aperture, about a plane between the expansion areas
when the male member is located within the female aperture.
Description
FIELD OF THE INVENTION
Structures are disclosed for creating a sub-floor or other
horizontal surface of hooks, the surface being formed from adjacent
anchor sheets connected by attachment pieces.
BACKGROUND OF THE INVENTION
Several earlier patents by one of the same inventors disclose an
anchor sheet which can be supplied as a small or large module, with
or without a pre-attached decorative covering. U.S. Pat. Nos.
6,306,477; 6,298,624 describe anchor sheets. Such anchor sheet is
also described in a more detailed way in international patent
application number PCT/CA00/00681, that was published under WO
00/74544 on Dec. 14, 2000, and U.S. application Ser. No. 09/008,584
filed Jan. 16, 1998, the specifications of all of which are
incorporated by reference. These earlier applications also disclose
the anchor sheet as a modular unit, many of which many can form a
contiguous mass of anchor sheets to be used as a sub-floor. A
decorative covering may be attached to the sub-floor, or the
sub-floor may be used as a finished floor when presupplied with a
decorative surface. Such a contiguous mass can be formed by
attaching the anchor sheets together by some form of overlap or by
abutting the anchor sheets to each other and using an overlap of
decorative covering or tape. Such mass can be free floating or
attached to the floor.
SUMMARY OF THE INVENTION
The current invention relates to improved anchor sheets and
attachment pieces which when abutted or overlapped can form a
generally-flat planar sub-floor or other surface for detachable
attachment of overlying decorative pieces, preferably with a hook
and loop system. The attachment pieces (also called attachment
devices or corner pieces, because they frequently fit into the
corner of another sheet), are really generally smaller anchor
sheets provided with one-half of a male or female connection, the
other half of the male or female connection being placed upon the
"main" anchor sheet. It should be appreciated, however, that the
size of the anchor sheet and anchor or attachments pieces is
somewhat arbitrary. It is possible to have quite small anchor
sheets and very large attachment pieces so that, in effect, there
is no distinction between the "attachment pieces" and the anchor
sheets. Effectively there are two sets of sheets which are
overlapped to form a planar surface. In practice, one of the sheets
will have a countersunk area of a thickness matching the thickness
of at least a portion of the other sheet, so that when overlapped,
a planer, substantially flat surface will be presented. Also,
generally in practice, one of the sheets will be of a size to
substantially cover the floor, with the other sheet being
substantially smaller (generally called the "attachment piece"),
for fitting into the countersunk area of the anchor sheet. Both the
anchor sheets and the attachment pieces themselves are preferably
made of polypropylene, or some other plastic. Such plastic may
expand and contract according to temperature and humidity. The
anchor sheets (and attachment pieces), are preferably designed to
have hooks on their upper surface, which receive a covering of
decorative pieces, which have loops complimentary to the hooks. If
the decorative pieces are, for example, carpet pieces, then it is
also advantageous to additionally allow for expansion and
contraction of the carpet pieces, by allowing for relative movement
of the anchor sheets. However, the anchor sheets themselves also
can expand and contract according to temperature and humidity, and
therefore, it is advantageous to allow for some expansion and
contraction in any event.
It is also advantageous to have the sheets connected together in a
positive way, but so as to prevent anchor pieces and anchor sheets
from rising up or riding up in relation to each other, which could
create a non-planar surface. Thus, it is helpful for the attachment
to have a positive connection in a direction at right angles to the
plane of the surface, for example a floor, while allowing for some
relative movement in a direction along or with the plane of the
floor. It is also advantageous if a connection can provide for
positive registration, so that the sheets are oriented and spaced
in relation to each other by the attachment piece.
Thus, in one aspect of the invention, there is provided a structure
for attachment between attachment pieces and anchor sheets, which
allows for relative movement between the attachment piece and each
anchor sheet, and therefore relative movement between anchor sheets
forming a planar surface. This structure can also create a suitable
space in between anchor sheets during installation, by setting a
connection point between the anchor sheets and the attachment
pieces. In another aspect of the invention, one of either the
anchor sheet or attachment piece has a male connection and the
other a female connection. One of the sheets has a countersunk area
containing the one-half of a male and female connection, and the
other sheet or attachment piece has the other half of the
male-female connection. In addition, either the female element is
provided with means for motion of the aperture into an expansion
space, or the male element is provided with means so that it can
move into an expansion space in a direction along the plane of the
floor.
Thus, in one aspect, the invention comprises a male and female
connection for overlapped sheets, comprising the following: (i) a
first anchor sheet having a substantially horizontal surface, and
having a portion countersunk from the horizontal surface at, at
least, one edge; and (ii) a central aperture within the countersunk
portion; and (iii) a second anchor sheet having at least an overlap
portion of a thickness to fit into the countersunk portion of the
first anchor sheet, to present a substantially planar surface, the
second sheet having a male member having a shaft sized to fit into
the aperture on the first sheet member, and having a second portion
larger than the aperture at the end of the shaft to create a cam
surface means to prevent removal of the male member from the
aperture, in which at least one of the male or female members have
expansion openings or areas of flexibility in the first or second
sheets surrounding either the male member or female aperture, to
provide for movement of either the male or female part, in a path
between the expansion areas.
In a second aspect, the invention comprises a first sheet member to
connect to an overlapped second sheet member to form a
substantially horizontal surface, comprising the following: (i) the
first sheet member having a first surface and a countersunk surface
below the level of the first surface; (ii) the first sheet member
having in the countersunk portion a first aperture; (iii) the
sheet, provided on two opposite sides of the first aperture with
expansion openings proximate to the first aperture, so as to create
areas in the sheet of increased flexibility, from either side of
the first aperture and a path substantially in the line drawn
between the middle of the second and third apertures.
In another aspect, the invention comprises a male sheet member to
connect to an overlapped female sheet member to form a
substantially horizontal surface, comprising: (i) a sheet member of
a thickness substantially the same as the depth of a countersunk
portion on a corresponding female sheet member and having a first
upper surface; (ii) a snap-fit means comprising at least two
flexible prongs projecting from the opposite bottom surface, and
having a normal memory position, of a size slightly larger than the
size of an aperture of a corresponding female sheet member, each
prong having a cam surface projecting radially outwardly.
In an additional aspect of the invention, the invention comprises:
(i) a first sheet member having a first surface and a countersunk
surface below the level of the first surface, the first sheet
having, in the countersunk portion, a first aperture of a diameter
x, and a channel of a smaller diameter, and a second sheet member
with at least an overlapping portion of a thickness matching the
thickness of the countersink of the first sheet member and, having
a male member with a stem and a head. The head fits into the
aperture of the first sheet member in a first location and the stem
has a thickness corresponding to the channel of the first sheet
member, so that the second sheet member can be inserted into the
first sheet member through the aperture and the shaft moved into
the channel to prevent upward motion of the head and of the first
sheet member in relation to the second sheet member, and in which
the male sheet member contains areas of expansion and flexibility
on opposite sides of the male member, so as to provide for flexible
movement of the male sheet member in relation to the second sheet
along a path drawn between the areas of flexibility surrounding the
male member. The areas of expansion may be apertures surrounding
the male or female members.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a portion of an anchor sheet showing a countersink.
FIG. 2 shows four anchor sheets overlapped on a floor.
FIG. 3 shows an anchor sheet and attachment device.
FIG. 4 is a perspective view of an attachment piece from below.
FIG. 5 is a perspective view of an anchor sheet to receive the
attachment piece of FIG. 4.
FIG. 6 is a plan view of an attachment piece and surrounding anchor
sheets with complementary first and second halves of a flexible
detachable attachment.
FIG. 7 is an alternative embodiment for a first and second anchor
sheet showing a male member with areas of flexibility.
FIG. 8 is a detail of the male member of FIG. 7.
FIG. 9 is a detail of the male and female member of FIG. 7 united
on a sheet, in plan view from above.
DETAILED DESCRIPTION
Preferably in the preferred embodiment, as shown in FIG. 1, an
anchor sheet 1 has a polyethylene layer 9, in which there is a
countersunk area 7 at (in this case), a corner. The sheet is made
of polyethylene and is substantially covered with hooks 4 that are
injection molded into the sheet. Details of this are described in
the corresponding applications entitled "System and Methods of
Manufacturing Hook Plates" and "Improved Anchor Sheet" by some of
the same inventors filed concurrently herewith, and in earlier
cases described earlier in this application, all of which are
incorporated herein by reference. The anchor sheet typically has a
resilient layer 5, but this is not necessary for the operation of
this invention. Contained within the countersunk area, in at least
one embodiment, is an aperture 15 and surrounding expansion areas
16 and 17, which will be described more fully in detail later.
Shown in FIG. 2, is a series of anchor sheets, which in this
embodiment have an overlapping area 23 and 25, but such overlapping
area is also not necessary for this invention. In FIG. 2, the
countersunk area for the attachment device is shown at 21.
FIG. 3, shows an anchor sheet also having a countersunk area 7, an
aperture 15 and expansion areas in the sheet 16 and 17. These are
areas of reduced strength, so as to allow for movement of the rim
14 around the aperture 15 into the expansion areas as will be
described later. FIG. 3 also shows an attachment device 31, which
typically will contain a male protrusion 33, projecting onto its
under-surface, and which will conform to and fit into aperture 15,
as also will be described in further detail later.
FIG. 4, shows in more detail, a male prong 33 as seen from below
attachment device 31. Registration members 35 are also placed
underneath attachment piece 31. Male prong 33 is a flexible
protrusion, which has a normal memory position as shown in FIG. 4,
which is slightly larger than aperture 39. It has a cam surface 37,
which contains an edge slightly larger than the corresponding
aperture 39 contained in the sheet 1. Shown in FIG. 5, is sheet 1
having aperture 39. There is also a corresponding indentation 41,
which matches with the registration member 35 to help centre the
snap-fit connection. In practice, male prongs 33 have sufficient
flexibility that they can move slightly into aperture 39, but are
normally in a position whereby cam surface 37 fits onto the edge 43
of aperture 39 to prevent disengagement of the attachment device 31
from the anchor sheet 1. As will be explained later, there are
apertures or expansion openings 45 through the polyethylene sheet
1, and surrounding the aperture 39 on opposite sides, so as to
create effectively a structure whereby the aperture 39 is
surrounded by a thin surrounding layer of plastic 47 as a rim on
two sides of the aperture, thus to allow the aperture to move in a
path between the two expansion openings 45. The movement of the
aperture allows for some movement of the whole connection between
the attachment device 31 and anchor sheet 1 as will be described
later. Some movement is also available because of movement of the
prongs 33. By appropriate placement of the aperture 39 and prongs
33 in of the overlap area of an attachment piece 31 and the overlap
of an anchor sheet 1, an appropriate space can be created between
the attachment piece and the anchor sheet. During atmospheric
expansion and contraction, the flexibility of prong 33 and the
flexibility of rim 47 and 48 around surrounding opening 39, allow
rim 47 and 48 to move into the expansion openings 45 as necessary
to accommodate expansion and contraction.
The prong 33 and rim 47 and 48 may be made from the same material
as the anchor sheet or the attachment piece, as long as the
material is sufficiently flexible. It is preferred that the
material be polypropylene or polyethylene. For example,
polypropylene such as that sold as STAMYLAN.TM. P112MN40 with an
ISO of 1873 indication of PP-H,MA-M400 is acceptable. This material
has a melt-flow index of 50 (T-230 degrees C., F=2.16 kg) a tensile
modulus of 1900 MPa, proportional strength of 35 MPa, ultimate
strain of greater than 50%, a density of 910 kg/m.sup.2, and a
melting point of approximately 160 degrees Celsius. The attachment
device 31 may include two registering pins 35 and two corresponding
indentations 41 for receiving pins 35. Pins 35 and indentations 41
co-operate to align the attachment piece 31 with the anchor sheet
1. This arrangement can encourage atmospheric expansion and
contraction to occur, in a direction along a line 572 or 574 that
passes approximately through the middle of expansion openings, as
shown in FIG. 6. In FIG. 6, attachment piece 430 has male members
432, 434, 436, and 438 on the bottom surface of its upper-disk,
with corresponding registering pins 440, 442, 444, and 446. These
fit into corresponding openings 448, 450, 452, and 454 and
corresponding pin receptacles 456, 458, 460 and 462. After the
prongs and registering pins are inserted into the corresponding
round opening and pin receptacles, atmospheric expansion and
contraction will be encouraged to take place generally through the
centres of the horseshoe openings 464, 466, 468 and 470, along
lines 574 and 572. It is not necessary to restrict the expansion
and contraction to these lines, but it is thought in practice that
this is the natural way that the sheets will expand and
contract.
Referring to FIG. 3, while in the above description, the first half
of the attachment device has been described as being an attachment
piece 31, and the second half has been described as being on an
anchor sheet 1, there could be a reversal of the male and female
members, however because the male member projects down into the
resilient layer 5, it is preferable to have the male member on the
attachment piece which is projecting into the resilient layer.
As shown in FIG. 7, male member 61 can also be provided with
expansion openings 63 and 65, which will allow for the male member
to move on the attachment device 31. In this embodiment, male
member 61 is inserted into keyhole 67, and then twisted to move
into channel 69. The flange or cam surface 71 on male member 61,
prevents the upward movement of attachment piece 31 once it has
been moved into channel 69. In addition, there are also
registration pins 73 on the underside of head 61, which can
register with small indentations 75 to locate the attachment device
33 in relation to the anchor sheet 1. As shown in FIG. 8,
registration pins can also be registration receptacles 77, so
co-operate with pins at locations 75 on anchor sheet 1. FIG. 8 also
shows the expansion opening 63 in greater detail. FIG. 9 shows the
attachment device 31 and the anchor sheet 1 shown in plan view from
above. Because of the countersink, attachment device 31 and anchor
sheet 1 are on the same plane, presenting a flat surface. Not
completely shown, but to be understood, is that typically the
anchor sheet will be covered in hooks (not shown), as will the
attachment device 31.
It is noted that those skilled in the art will appreciate the
modifications of detail may be made from the embodiments described
herein which would come within the spirit and the scope of the
invention as described in the following claims.
* * * * *